Textile lubricant



United States Patent 3,341,452 TEXTILE LUBRICANT Leigh W. Cooley, Greenville, N.C., assignor to E. I. du Pont de Nemonrs and Company, Wilmington, Del., a corporation of Delaware No Drawing. Filed Feb. 25, 1965, Ser. No. 435,322 5 Claims. (Cl. 252-83) This invention relates to a novel composition of matter and more particularly it concerns a novel high temperature lubricant for textile fibers and the fibers and yarns produced.

In the commercial production of synthetic, continuousfilament yarns, it is common practice to apply to the filaments lubricating compositions to reduce the tendency towards breakage of the individual filaments when they are subjected to various mechanical strains. T hese textiletreating compositions are referred to as finishes and since the finish is commonly applied during the spinning step, they are frequently referred to as spin finishes. Such finishes serve to lubricate the yarn during the manufacturing process and in subsequent handling operations. While satisfactory for some end-uses, such as weaving and knitting, these spin finishes are not satisfactory for high-temperature environments. Conventional spin finishes contain selected low-viscosity lubricants in order to obtain the lowest possible yarn tensions. However, these lowviscosity lubricants volatilize during high temperature processing and the deterioration of the lubricating system causes excessive broken filaments and a loss in yarn strength. Further, the formation of highly objectionable fumes and condensates can create serious health and housekeeping problems.

It is an object of this invention to provide a textile finish suitable for satisfactory high-temperature processing of synthetic continuous-filament yarns.

This and other objects are attained with this invention in a finish composition comprising, by weight, 40 to 60 parts of coconut oil, 5 to 20 parts of a soft hydrocarbonwax and 25 to 50 parts of a nonionic emulsifier. This composition is dispersed in water to form an aqueous emulsion, which is then applied to textile yarns whereby there is obtained a treated yarn having outstanding high-temperature processing properties.

As is known, polyester yarns are preferably drawn at an elevated temperature, and this is advantageously accomplished in a heated finish bath. Suitable aqueous finishes which are stable under the temperature conditions required for optimum drawing performance and which are satisfactory for subsequent processing, are limited in number by these strict requirements. As previously indicated, these finishes are deficient with respect to high temperature processing. Now, by utilizing the unique composition of this invention, standard commercial production can be modified for high-temperature end uses as the need requires and without the necessity of installing otherwise duplicate facilities. The finishes of this invention are highly compatible with the hot drawbath finish and when applied thereover contribute the properties required for successful high-temperature performance.

The major component of the finish is coconut oil, particularly in the refined grades, which is eminently suited for application to yarns intended for high-temperature ice peratures. The amount of coconut oil used in the composition may vary from about 40 to 60 parts by weight.

The soft hydrocarbon-wax possesses, to a high degree, the required high-temperature lubricating characteristics. The soft wax is of mineral oil origin, and comprises an intimate mixture of oil and wax. The use of this mixture does not result in the formation of gel structures as oc-v curs when, for example, a relatively oil-free microcrystalline wax is used at an equivalent concentration. The soft wax generally consists of about 35 to 40% oil and 60 to of a hydrocarbon wax, and has a melting point below about 35 C. Both the oil and wax are predominantly naphthenic in character, i.e., the hydrocarbon molecules contain condensed aliphatic rings. The molecular weight of the naphthenic hydrocarbons range from about 600 to about 800 with the higher molecular weights being representative of the wax. Small amounts of other hydrocarbons, e.g., those characteristic of the higher viscosity lubricating oils may also be present. The mixtures useful in the practice of this invention do not form definitive crystalline patterns but maintain, at room temperature, an unctous consistency. While any mixture having the visual appearance of a pasty mass may be used, mixtures having a high proportion, e.g., 50 to by weight, of the wax constituents are preferred. A commercially available product of this character is TFO-8 0f the Shell Oil Company, and is termed a bright stock soft-wax, and is that employedin the examples given here-. inafter. The mixtures defined above are diflicult to emulsify; however, surprisingly they have been found to add to the stability of coconut oil emulsions, perhaps by acting as a protective colloid. The amount of the soft hydrocarbon-wax used in the novel finish compositions may vary from about 5 to 20 parts by weight. For optimum results the amount used should be comparatively small and, in general, should correspond to about 1 part for each 5 parts of'cocouut oil.

The lubricating components of these novel finishes are preferably applied to the yarn in the form of an aqueous emulsion. The lubricants are emulsified by blending them together with an emulsifier and dispersing the blend in water with agitation. The emulsifiers found to be most effective are of the nonionic type and preferably are those based on condensates of ethylene oxide. In order to achievemaximum stability, it has been found that the emulsifier content must be relatively high with respect to that of the lubricants. Good stability is obtained with about 25 to 50 parts by weight of emulsifier. At such high emulsifier concentrations, ionic emulsifiers, e.g., fatty acid soaps, result in excessive deposits on surfaces in contact with the yarn. However nonionic emulsifiers based on ethylene oxide contribute lubricating properties to the composition and their use does not result. in the undesirable formation of smoky fumes or gummy deposits. Nonionic emulsifiers which do not contain ethylene oxide, e.g., glyceryl monooleate, sorbitol tripalmitate, may he used to impart special properties, such as improved wetting action, to the blend 'but the proportion used should be relatively small, e.g., 1 part to each 5 to 10 parts, by weight, of the emulsifier based on ethylene oxide. The

aqueous emulsion may contain between about 1 and 30 parts by weight of solids, i.e., non-aqueous constituents. Application to the yarn may be made by any convenient means such as by passing the yarn across the face of a roll running in a trough containing the emulsion. The amount of solids applied to the yarn may vary from about 0.1% to about 1. based on the total weight of the resulting yarn, and preferably, will be about 0.3 to 0.6%.

As indicated above, the novel compositions of this invention are preferably applied to a yarn which has previously been coated with a finish, i.e., it is used as a secondary, or overlay, finish. With respect to the previously applied finish, the amount of overlay finish should constitute about 20' to about 50%, by weight of the total amount applied. Application at these levels will be suflicient to provide the lubricating properties required for high-temperature processing and will minimize or eliminate the propensity of the primary finish to create undesirable fumes or condensates. In general, the higher amounts will be applied to low-denier-per-filament yarns, i.e., yarns having a d.p.f. of about 1 to 3. Low-denier-perfilament yarns are highly sensitive to tension levels and disastrous consequences can result when such yarns are stripped of their protective lubricating coating by the deg-radative action of heat. For most textile uses wherein the yarn is exposed to high temperatures, i.e., temperatures of 150 to- 300 C. and more, the total amount of finish will not normally exceed about 1.0% based on the weight of the resulting yarn.

In keeping with conventional practice, minor amounts of additives such as, for example, bactericides, tinting agents, antioxidant-s, buffering agents and the like may be included as desired.

The invention will be described further in conjunction with the following examples in which parts and percentages are by weight, unless otherwise specified.

Example I Polyethylene terephthalate polymer is spun in conventional manner into a 54-filament yarn. The yarn is drawn in much the manner described in U.S. Patent 3,045,315 to a denier of 70. The hot draw-bath is a 15%, by weight, aqueous emulsion of a composition consisting of, by weight, 50 parts of isocetyl stearate, 25 parts of sodium di(2-ethylhexyl) sulfosuccinate, 25 parts of the material obtained by condensing 1 mol of stearyl alcohol with 3 moles of ethylene oxide and 1 part of the triethanolamine salt of oleic acid. The yarn, of which 0.4% of its weight is the finish solids, has a tenacity of 5.30 grams per denier. This yarn -is designated a control yarn.

Into a stainless-steel container are placed, by weight, 50 parts of refined coconut oil, -10 parts of a soft hydrocarbon-wax, 35 parts of an ester of a sorbitol-ethylene oxide condensate, and parts of the material obtained by condensing nonylphenol with ethylene oxide, using about mols of ethylene oxide for each mol of nonylphenol. The soft hydrocarbon-wax consists of an intimate blend of about 37%, by weight, of a high molecular weight naphthenic oil and about 63%, by weight, of a naphthenic wax, and has a melting point of about 34 C. The molecular weight of the blend components ranges from about 600 to about 800. The ester is obtained by condensing ethylene oxide and sorbitol using about 30 mols of ethylene oxide for each mol of sorbitol and esterifying this condensate, with a mixture of oleic acid and lauric acid having a ratio of 4 mols of oleic to one mol of lauric acid, using 5 mols of the mixed acid for each mol of condensate. This mixture is then heated to 60 C., with agitation, until a homogeneous liquid is obtained. The liquid is then cooled to 50 C. and 20 parts, by weight, are added to 80 parts, by weight, of water heated to 50 C. to form a stable emulsion containing 20% solids.

A portion of the control yarn is then passed Over a 4. finish roll running in a trough containing this 20% emulsion. The yarn so produced contains 0.3%, by weight, of the solids of this emulsion, based on the total weight of the yarn. This yarn is then false-twist textured using commercially available equipment (Leesona Corp., Superloft Model 553). In this process the yarn is in contact with a metal plate 27 inches in length (69 cm. in length) heated to a temperature of 230 C. After false-twlse texturing this yarn has a tenacity of 4.30 grams per denier.

A similar run using the control yarn having no added finish produces a yarn having a tenacity of only 3.08 grams per denier.

Example II Example I is repeated except that the yarn is stocked to similar false-twist texturing equipment (Whitin Machine Works, ARCT Model FT3) in which the metal surface is 48 inches cms.) in length and is heated to 220 C. In this high temperature processing, the yarn carrying a composition of this invention has a broken filament index of 0.31. The broken filament index is defined as the number of broken filaments in 18 thousand yards, (16.5 thousand meters) of yarn.

Example III Example I is repeated except that the yarn produced is a 70-denier 14-filament yarn and contains 0.1% of the finish composition of the invention, based on the total weight of the yarn. This finish results in the production of a high quality, uniformly textured yarn without the production of smoking and fuming.

While the novel compositions of this invention have been described and exemplified with respect to polyester yarns, they are also suitable for use on other synthetic yarns, e.g., polyamide yarns, wherein the need is for a textile lubricant suitable for high-temperature processing. Further, these compositions may be the sole material applied to the yarn and, particularly, for polyamide yarns, may be applied prior to drawing. In addition it should be apparent that the invention can be practiced with spin or other type finishes that are different from that employed in the specific examples. Other changes can also be made without departing from the scope of this invention.

What is claimed is:

1. A finish composition for application to yarn for high temperature processing comprising, by weight (a) 40 to 60 parts of coconut oil,

(b) 5 to 20 parts of a soft hydrocarbon-wax which is an intimate mixture of naphthenic oil and wax having a molecular weight in the range of about 600 to 800 and a melting point below about 35 C., and

(c) about 25 to 50 parts of a condensate of about 10 mols of ethylene oxide and a mol of nonylphenol, and an ester of a mol of the condensate of about 30 mols of ethylene oxide and a mol of sorbitol with 5 mols of a mixture containing 4 mols of oleic acid and one mol of lauric acid.

2. A finish composition in accordance with claim 1 containing, by weight, 50 parts of the coconut oil, 10 parts of the soft hydrocarbon-wax, 35 parts of the ester and 5 parts of the nonylphenol-ethylene oxide condensate.

3. An emulsion comprising about 1 to 30 percent by weight of a composition in accordance with claim 1 and the remainder water.

4. Textile yarn particularly suited to high temperature processing comprising yarn composed of continuous filaments of a synthetic polymer containing, based on the weight of the resulting yarn, from about 0.1 to one percent of a composition containing, by weight (a) 40 to 60 parts of coconut oil,

(b) 5 to 20 parts of a. soft hydrocarbon-wax which is an intimate mixture of naphthenic oil and wax having a molecular weight in the range of about 600 to 800 and a melting point below about 35 C., and

(0) about 25 to 50 parts of a condensate of a mol of nonylphenol and about 1'0 mols of ethylene oxide, and an ester of a mol of the condensate of about 30 mols of ethylene oxide and a mol of sorbitol with 5 mols of a mixture containing 4 mols of oleic acid and one mol of lauric acid.

5. A textile yarn in accordance with claim 4 where said yarn is -a polyester.

6 References Cited UNITED STATES PATENTS 2,974,106 3/1961 Fronmuller 252-38 X 3,113,369 12/196-3 Barrett et 'al. 2528.6 X 3,248,258 4/1966 Coats 2528.6

LEON D. ROSDOL, Primary Examiner. J. T. FEDIGAN, Assistant Examiner. 

1. A FINISH COMPOSITION FOR APPLICATION TO YARN FOR HIGH TEMPERATURE PROCESSING COMPRISING, BY WEIGHT (A) 40 TO 60 PARTS OF COCONUT OIL, (B) 5 TO 20 PARTS OF A SOFT HYDROCARBON-WAX WHICH IS AN INTIMATE MIXTURE OF NAPHTHENIC OIL AND WAX HAVING A MOLECULAR WEIGHT IN THE RANGE OF ABOUT 600 TO 800 AND A MELTING POINT BELOW ABOUT 35*C., AND (C) ABOUT 25 TO 50 PARTS OF A CONDENSATE OF ABOUT 10 MOLS OF ETHYLENE OXIDE AND A MOL OF NONYLPHENOL, AND AN ESTER OF A MOL OF THE CONDENSATE OF ABOUT 30 MOLS OF ETHYLENE OXIDE AND A MOL OF SORBITOL WITH 5 MOLS OF A MIXTURE CONTAINING 4 MOLS OF OLEIC ACID AND ONE MOL OF LAURIC ACID. 